Apparatus for making print rollers and the like



j. 2l, l936. W, M GREENE ET AL 2,028,699

APPARATUS FOR MAKING PRINT' ROLLERS AND THE LIKE Filed Oct. 9, 1933 2sheets-sheet 1 3mm i936. WMGREENE EN, www- APPARATUS FOR MAKING PRINTROLLERS AND THE LIKE Filed Oct. 9, 1,933 2 Sheets-Sheet 2 Patented Jan.21, 1936 UNITE STATES ATSENT OFFIQE APPARATUS FOR MAKING PRINT ROLLERSAND THE LIKE New York Application October 9,

9 Claims.

This invention relates generally to a method of and apparatus for makingcastings and more particularly to the casting of print rollers made ofan aluminum alloy.

One of its objects is to provide a method and apparatus of thischaracter wherein the castings are made in a permanent chill mold andwherein an even and uniform distribution of the molten metal in the moldis effected to intensify the metal and afford a compact smooth surfacesuitable for print rollers and the like.

Another object of the invention is the provision of a method andapparatus for making sound aluminum alloy castings, which combinessimplicity of mold construction and assembly with ease of operation andreduces to a minimum the oxidation of the metal during the pouring ofthe mold.

Afurther object-is to provide novel means for gating the mold so as toefectually and positively control the flow of the molten metal todistribute it uniformly over the entire length of the mold; to causepooling of the metal at the gate and reduce to a minimum the length oftravel of the molten metal and to prevent the gathering of oxide andimpurities while the metal flows or drains into the mold.

A stil-l further object of the invention is vto provide-a method of andapparatus for casting print rollers of an aluminum alloy which embodiesa permanent mold and a metal core so designed and constructed as toprevent distortion of the core and cracking of the cast roller duringmolding thereof, and which at the same time allows the metal to ow intothe mold only as fast as it will chill Without setting until themold-cavity isrlled.

Other features of the invention reside in the construction andarrangement of parts herein- 40 after described and particularly pointedout in the appended claims.

In the accompanying drawings:-

Figure 1 is a top plan View of the permanent mold employed for casting aprint roller, one of the mold sections being shown in dotted lines in aretracted position for assembling the core or removing the nishedcasting. Figure 2 is a central longitudinal section of the mold taken onlineZ-Z, Figure l. Figure 3 is an enlarged cross section thereof takenin the plane of line 3 3, Figure 2. 'Figure 4 is a detached perspectiveView, partly in section, of the core parts of the mold. Figure 5 is aperspective view of the supporting member or mandrel for the core.

1933, Serial No. 692,746

Figure 6 is a perspective View of `the finished print roller casting.

Similar characters ,of reference'indicate corresponding parts throughoutthe several views.

With our improved method of and apparatus for making print rollers froman aluminum alloy, the use of sand cores and molds is dispensed with anda permanent chill mold and metal core are employed, these parts beingconstructed and designed to not only expeditiously produce uniformlysound and perfect castings with a dense, smooth printing surfaceappropriate for the cutting of patterns thereon for the printing of`Wall paper and the like, but also to produce castings free fromblowholes and like imperfections and, i

by the method employed, prevent the introduction of oxide and impuritiesinto the molten metal While the same is poured or drained into themold-cavity.

Referring now to the drawings, wherein is illustrated the preferredembodiment of our invention, attention being directedfirst to Figure y6,I indicates one of the cast print rollers made in accordance with theinvention from an aluminum alloy composed for example, of aluminum, tinand zinc, this roller being cast hollow and closed at each end'by anintegrally-cast `head H having an opening I2 therein containing akey-Way I3 for mounting it on the shaft of the printing press.

In VFigures 1, 2 and 3, the chill mold and the metallic core for castingthe print roller are in their assembled positions ready for pouring themolten metal. As there shown, the chill mold preferably consists of Vtwocompanion metallic sections I4, I5 which may be suitably supported in ahorizontal position on a suitable frame or platform (not shown) with themeeting joint of the sections disposed in a vertical plane and with oneof the sections movable relatively to the other section to eiect theinsertion of the core-assembly preparatory to pouring or to effect theremoval of the casting and its core-assembly after the pouringoperation. Each one of the moldsections contains in its inner wall alongitudinal mold cavity it of substantially semi-circular shape incross-section, which, together with the companion cavity of the othersection, jointly form a cylindrical cavity for producing the cylindricalwall of the print roller. At lts ends the mold-sections have companionend plates Il and i8, respectively, which form end closures for lthecavity I6.

Applied to the top side of the mold sections I4, I5 and preferablylongitudinally split in the plane of the joint thereof lis a gate orpouring well indicated generally by the numeral I9 which may berectangular shape in plan, and which is formed in part by achannel-shaped member including side walls 23 and a bottom wall 2Iseated in companion longitudinal recesses 22 formed in the top sides ofthe corresponding mold-sections I4, I5, the bottom face oi the channelbeing disposed substantially tangentially to the top of the moldcavitiesI6. The end walls of the gate or pouring Well are produced in part bythe opposing inner portions of the companion plates I1 and in part bythe opposite or closed ends 23 of the recesses 22, as shown in Figures land 2. As also seen in Figure 2, the top edges of the end plates I1, I1and the corresponding top edges of the recesswalls 23 constitute a gaugefor aiding the molder in determining the depth of molten metal which maybe poured into the gate or well I9. In its bottom wall 2i the gate isprovided with a plurality of long-narrow discharge openings or slits 24for conducting the molten metal in a thin or sheet-like stream from thegate into the mold cavity. As shown in Figures l and 3, these openingsare disposed longitudinally of the mold and centrally of the bottom wallof the gate in the plane of the meeting joint oi the mold, and in theexample shown, two of such openings are provided which are spaced apartlengthwise to provide between them a solid pouring face 25 in thegate-bottom 2i and onto which the metal from the Crucible 25 is directlypoured, in the manner shown in Figure 2. By this construction, thedirect flow of the metal into the mold-cavity is prevented and the metalis caused to pool in the gate, thus holding the oxide and impuritieswhile the metal drains in thin sheets or streams through the dischargeopenings 24 into the mold. This method of gating eifectually controlsthe flow of the molten metal and distributes the same uniformlythroughout the entire length of the mold; it reduces to a minimum thelength of travel of the molten metal and thereby prevents the gatheringof oxide; and at the same time it allows the metal to flow into the moldonly as fast as it will chill without setting until the mol'd is filled.

The bottom wall of the gate on laterally opposite sides of the openings24 is preferably beveled or sloped inwardly and downwardly in the mannerindicated at 21 in Figures l and 3 to provide the discharge openingswith comparatively thin knife-like longitudinal edges, whichconstruction, together with the accumulated metal in the gate, permitsdrawing from the gate for final shrinkage of the cast roller. It willalso be noted, from Figure 3, that the top edges of the mold-cavities I5terminate short of each other below the gateopenings 24 to provide aninlet 28 to the moldcavity.

The metallic core used in the casting of the hollow print roller ispreferably in the form of a pipe 29 of sheet metal or like materialclosed at its ends by flanged metallic heads or caps 30 each having anaxial opening 3l therein containing a key-way 32. This core and itsheads are cast directly with and form a part of the completed printroller. To prevent distortion of the core-pipe 29, it may providedbetween its ends with one or more annular beads 33.

For the purpose of supporting the core-pipe within the mold-cavity, amandrel in the form of a tube 34 is provided which is adapted to extendat its ends through suitable axially-alined openings 35 formed in theend plates I I, I 8 of the mold-sections I4, I5. Slidably mounted onthis mandrel adjacent to its ends, are substantially cone-shaped collarsor sleeves 36 and 31, respectively, which are provided with keys 38adapted to engage the corresponding key-ways 32 in the pipe-heads 3B.The inner coupling collar 31 is provided with a circular stop-oli plateor centeringdisk 39 which is of a diameter to t snugly within themold-cavity I6, in the manner shown in Figure 2, and which serves to notonly center the core-pipe 29 in the mold but which also constitutes theinner abutment wall of the mold cavity. In other words, one end of themold cavity for a given length print roller is formed by the plates I1,I1 at the right hand end of the mold, while the opposite end of the moldcavity is formed by the circular plate 39. This centering plate togetherwith its coupling collar 31 is held against endwise outward displacementby a spacing sleeve 46 surrounding the adjoining end of the mandrel 34and a spring 4I interposed between said spacing sleeve and the platesI8, I8, at the left hand end of the mold, as clearly shown in Figure 2.The companion or outer coupling collar 36 has an extension 368- thereonwhich is adapted to engage the opening 35 of the end plates I1 andthereby support the outer end of the mandrel 34 and center thecorresponding end of the core'29 in the mold cavity. These couplingcollars and keys constitute a part of the core and provide the openingsI2 and key-ways I3 in the cast roller III.

For casting print rollers of different lengths, corresponding spacingsleeves 40 of different lengths are employed to properly locate thecoupling collar 31 and its plate 39 at the proper distance from theright hand end of the mold cavity.

In assembling the core 29 and' its associated parts, the mandrel 34 isinserted through the end openings 3| of the core-heads 33; the couplingcollar 35 is then slipped over the right hand end of the mandrel and itstapered portion forced into gripping engagement with the correspondingcore-head 3i! with its key 38 engaging the keyway 32 of the companionhead-opening 3l, after which the companion coupling collar 31 with itscombined centering and closure plate 39 is slipped over the opposite endof the mandrel with its tapered portion forced into like iittingengagement with the opposite head 3G of the core-pipe. The sleeve 48 andspring 4I are then applied to the left hand end Vof the mandrel and thewhole core-assembly inserted as a unit into the mold cavity I6, it beingunderstood that the mold-section I5 is in its retracted, dotted lineposition shown in Figure 1 at this time. Upon supporting the ends of themandrel in the openings 35 of the mold and properly centering the core29 in the mold, the mold-section I5 is shifted toward the companion moldsection I4 and clamped firmly thereto, whereupon the mold is ready toreceive the molten metal to cast the print roller.

In pouring the mold, the Crucible is located at a point directly overthe solid pouring face 25 of the gate I9, so that when the Crucible istipped the molten metal will strike such face and break or intercept thedirect flow of the metal into the mold. Thereupon the metal pools in thegate to hold'the oxide and other impurities therein while the metaldrains in thin streams through the discharge openings 24 into themold-cavity. For the purpose of providing for the escape of the gases inthe mold, the mandrel 34 has vents 42 therein.

After the casting has properly set, the movable mold-section I5 isunclamped and retracted from the companion mold-section I4, after whichthe casting, together with the entire core assembly, is removed. Themandrel 34 and core-forming coupling collars 36 and 31 are then removed,and to eiect the ready disconnection of these collars from the ends ofthe roller without cracking its head-ends, said collars are preferablysplit as indicated at 43.

We claim as our invention:-

1. An apparatus of the character described, comprising a chill includingcompanion mold'- sections having end walls and shaped to form a cavity,a pooling gate applied to the chill immediately above and substantiallycentrally of the cavity to receive the molten metal and having aplurality of narrow discharge openings in its bottom and at spacedintervals for directing the molten metal in a thin stream into the moldcavity, sai-d openings terminating substantially at the periphery of thecavity in knife-like horizontal edges for permitting drawing from thegate for final shrinkage of the casting, a metal core, and means forsupporting and centering the core in said cavity, said means including ahollow mandrel extending through the core and having collars slidablymounted thereon and detachably fitted in said core and supported at itsends in the chill, said mandrel having vent opening therein.

2. An apparatus of the character described, comprising a chill includingcompanion mold-sections having end walls and shaped therebetween to forma cavity, a gate applied to said chill in communication with its cavity,a metalcore, means detachably tted in said mold-cavity for supportingand centering the core therein, said means at one end engaging theadjoining end wall of the chill and provided at its opposite end with amember adjustable axially of the moldcavity in accordance with thelength of the casting to be made, said member being shaped to t themold-cavity and forming a closure for the corresponding end of saidcavity, and means interposed between said closure member and theadjoining end wall of said cavity for holding such member in apredetermined set position.

3. An apparatus of the character described, comprising a chill includingcompanion moldsections having end walls and shaped therebetween to forma cavity, a gate applied to said chill in communication with its cavity,a hollow, metal core having openings in its ends, and means detachablyfitted in said mold-cavity for supporting the core therein, including amandrel extending through said core and supported at its ends in the endwalls of the chill, and coupling collars constituting a part of themetal core and slidingly mounted on said mandrel for frictional clampingengagement with the end-openings of the core.

4. An apparatus of the character described, comprising a chill includingcompanion moldsections having end walls and shaped therebetween to forma cavity, a gate applied to said chill in communication with its cavity,a metal core having end heads containing aXially-alined openings andkey-Ways therein, and means detachably tted in said mold-cavity forsupporting the core therein, including a mandrel extending axiallythrough the core and its head-openings and supported at its ends in theend walls of the chill, and coupling collars constituting a part of saidcore slidingly mounted on said mandrel for engagement with the core-headopenings, said collars having keys thereon engageable with the key-Waysin said head-openings.

5. An apparatus of the character described, comprising a chill includingcompanion moldsections having end walls and shaped therebetween to forma cavity, a gate applied to said chill in communication with its cavity,a metal core having end-heads, and means detachably tted in said moldcavity for supporting and centering the core therein, including amandrel extending through the core and coupling collars applied to saidmandrel for detachable interlocking engagement with the end-heads ofsaid core, one of said collars engaging the adjoining end wall of thechill and the other collar having a member thereon tted in andconforming to the mold-cavity and constituting a closure for theadjoining end of said cavity.

6. An apparatus of the character described, comprising a chill includingcompanion moldsections shaped to form a cavity, a gate applied to saidchill in communication with its cavity, a

l metal core, and means for supporting and centering the core in saidcavity, said means including a hollow mandrel extending through the coreand having shiftable collars thereon detachably fitted in said core andsupported at its ends in the chill, said mandrel having vent openingstherein.

'7. An apparatus of the character described, comprising a chillincluding companion moldsections shaped to form a cavity, a gate appliedto said chill in communication with its cavity, a metal core, andunitary means detachable from said core for supporting and centering thecore in said cavity, said means including a vented mandrel extendingfreely through the core, coreforming collars slidingly tted on saidmandrel for coupling engagement with the opposite ends of said core, amember applied to one of said collars and engaging the mold-cavity andconstituting a closure for the adjoining end of said cavity, and aspacing sleeve and spring applied to said mandrel and interposed betweensaid closure member and-the adjoining end wall of the chill.

8. A core for use in casting print rollers and the like, comprising ahollow cylindrical body having end-heads containing axially-alinedopenings, a mandrel extending axiallythrough said body an-d itsopenings, and coupling collars constituting a part of the core-body andslidingly mounted on said mandrel for engagement with saidhead-openings.

9. A core for use in casting print rollers and the like, comprising ahollow cylindrical body having end-heads containing aXially-alinedopenings and key-ways therein, a mandrel extending through said body andits head-openings, and coupling collars constituting a part of thecore-body and slidingly mounted on said mandrel for detachableengagement with the corehead openings, said collars having keys thereonengageable with the key-ways in said openings.

WILLIAM M. GREENE. PAUL E. LUTHER.

